Aggregates Manager’s Guide to ConExpo-Con/Agg 2008

With so little time and so much trade show floor to cover, let our preview of the big show streamline your search for the best in show.

by Therese Dunphy, Editor-in-Chief

Highway portable stacker

Thor Global features its new T150-20, a 48-inch by 150-foot highway-portable telescopic stacker. The unit can be folded up and ready for transportation or unfolded and ready for production within 15 minutes, the company says, and can stockpile up to 2,000 tons per hour. The company attributes its experience in cranes in helping it to design the correct balance of weight and structure to create a high-throughput, strong machine. As part of the ThorStack 2 line, the new stacker features a quick-release system that allows the operator to easily engage or disengage the radial drive system within three minutes. It also boasts zero-speed switches on inner and outer conveyors to protect the stacker from overloading if the belt is broken or slips.

Astec Mobile Screens will showcase its expanded line of Fold ’n Go mobile screening plants. Its new Fold ’n Go 2516KT track plant is designed to meet high volume demands in quarrying, sand and gravel, and recycling operations. Powered by a 97 horsepower Caterpillar engine, the portable screen features easy-to-reach engine controls and central grease points. The 5- by 16-foot double-deck screen is supported by rubber torsion springs that allow for a smoother operation. Operating angles of the screen box can be hydraulically adjusted for various production and material separation needs.

Innovative Equipment Solutions will introduce its new Neptune Series of fully automated, drive-through wheel wash systems, which can be configured with one-, two-, or three-tire revolutions of cleaning to eliminate job site track out. Featuring concrete or galvanized steel sidewall construction, the system can be used in either permanent or temporary installations. All models are engineered with a fully automated, closed-loop water recycling and solids separation process. The series is said to feature a high-volume, low-pressure water design to prevent overspray and the knocking of oil and grease from the truck chassis. Its extra-wide, 42-inch wash elements flex the tire tread open to allow the high water volume flow to flush the tires clean while a highly focused spray is easily achieved with adjustable nozzle assemblies.

Polydeck Screen Corp. will debut its PipeTop II Stringer System, a new design that maximizes versatility from a single frame. Available in three forms — bundled rails for a new screen deck, jigged conversions for changing out an existing frame, or a complete screen deck frame to retrofit an older shaker — PipeTop II is said to offer a variety of production benefits. Its 1/2-inch rails, when coupled with Polydeck’s Maxi screen panel designs, provide a high open area that may match wire cloth in many cases. It also offers multiple fastening options from a single frame including PolySnap and traditional pin-style versions. The fastener heads are polyurethane and screw into steel ferrules on the frame rails. If a fastener head becomes worn, it can be removed and replaced individually rather than replacing an entire frame. For applications requiring a changeover to wire cloth, crown adapters fit both fastener head types and offer the ability to change between screen media with a minimal investment of time and money.

Atlas Copco plans to showcase its ROC D7C, a silenced SmartRig surface crawler. SmartRig is a concept that facilitates a variety of automation in drill rigs. The hardware is designed to operate in every possible weather condition, and the software can be upgraded on site. The units have built-in logging and monitoring functions as well as support for diagnostics and fault finding. Through PC software, the SmartRig control system electrical signals are generated to control the hydraulic valves. This concept of a “dry cab” has no hydraulic pipes or gauges and reduces noise for the operator. The amount of hydraulic and electrical cables is reduced, which frees up space in the cab and increases operator visibility. The use of a laser plane creates consistency in hole depth for improved fragmentation of blasted rock while an automatic rod adding system, AutoRAS, enables the operator to drill automatically to a given depth.

Libra Systems will unveil its Self-service Kiosks at ConExpo-Con/Agg 2008. The kiosks allow material suppliers to increase revenue by handling more truck traffic without a corresponding increase in the number of operators. The kiosks are said to enable extended operating hours at a lower cost, free scale house operators to handle other responsibilities, reduce data entry and ticket errors, reduce in-yard times, and improve customer satisfaction. Units are available that handle all of the various roles in ticketing including check-in, check-in with tare, checkout, and ticket printing. They also can be configured to control external equipment such as traffic lights and gates.

HCSS will demonstrate its HeavyJob field management software, The Dispatcher resource management software, and HeavyBid estimating software at ConExpo-Con/Agg. The Dispatcher’s integrated GPS feature, which allows construction company managers to make decisions based on accurate equipment information, will be highlighted. New safety and reporting features for HeavyJob will also be demonstrated.

Terex Pegson’s ConExpo-Con/Agg lineup includes three new track-mounted crushers: the large XA750 jaw, the XV350 vertical shaft impactor, and the SH250 horizontal impactor. The XA750 is an entirely new jaw plant for larger quarry and recycling applications. Featuring a modular design for maximum capacity, it boasts a hopper/feeder section with live pre-screen that is removable for transport if required. A one-piece hydraulically raised/lowered product conveyor, extended dirt and fines conveyor, and Jaques 55- by 35-inch jaw round out the plant. The XH250 HSI targets smaller recycling and quarry operations while the XV350 VSI boasts an updated 1300 Maxtrak chassis.

Sturtevant will feature live demonstrations of crushed stone being de-dusted to minus 200-mesh fines without water during ConExpo-Con/Agg. Sturtevant’s Whirlwind Air Classifier incorporates an internal fan and rejecter blade classification system. Its self-contained design does not require cyclones, valves, dampers, ductwork, external fans, or the additional supports required to handle these components. The feed is belt conveyed into the classifier by gravity. Rotating selector blades control the particle size of the fines removed by the air to improve the de-dusted product yield. Stationary units can produce up to 800 tons per hour.

Continental Conveyor & Equipment Co. plans to roll out its Continental JLV pulleys, which are designed around the application of keyless locking elements between end-discs and shafts. Widely used in high-tension pulley applications, the company expanded the use of the technology below the level of high-tension pulleys. Key advantages include the following: end discs are made from solid plates rather than weld-in hubs; the bending moment at the hub is reduced without sacrificing strength and durability; lighter pulley construction provides similar durability to heavier pulleys; and the units feature a stress-balanced design that matches stresses and deflections of all pulley components and thereby eliminates high-stress areas in the pulley. The Continental JLV pulleys are available in mine-duty turbo-disc, engineered turbo-disc, heavy-duty T-bottom, and dead-shaft designs.

Grasan will highlight its custom design capabilities in road-portable, pit-portable, and stationary equipment and systems for crushing, screening, handling and storage of aggregates; recycling of concrete and asphalt rubble; conveying and stacking; and special applications in bulk material handling and processing. One of the company’s newest developments is a line of large, track-mounted primary crushing plants that will be largely custom designed and built to meet individual customer needs and specifications. The plants can be built around any crusher — impactor or jaw — that best fits the producer’s operation.

Fisher Industries will feature its 13-foot diameter Fisher Air Separator. It said to effectively remove unwanted fines from aggregate products, bringing otherwise rejected material into specification. Its ability to “dry” process materials and remove excess fines promotes an efficient and clean operation. The air separator requires minimal maintenance and can process up to 150 tons per hour. It is designed with the mobile producer in mind and sets up in as little as two hours. Portable and stationary models are available.

The Safe-Guard line from ASGCO works on CEMA B, C, and D series idlers up to 7 inches in diameter, and now has now been expanded to include CEMA E & F return rollers. The transverse support of the new heavy-duty idlers is angled to provide a more “robust” design that prevents bending and is sized to fit over CEMA E & F return roller brackets, according to the manufacturer. Both the mounting brackets, as well as the end plates, are made from powder coated A-36 steel. The return idler guard was designed to prevent injuries from pinch points and to catch the return idler if it should fall, protecting workers from the hazard of contacting the exposed idler. Everything in the Safe-Guard line is fully adjustable for a wide range of idler sizes and belt widths up to 96 inches.

Major Wire Industries Ltd. will showcase its newest innovation — Flex-Thane — a flat-deck version of its Flex-Mat screen media that is said to increase production. It combines the efficiency and performance of the Flex-Mat technology with the easy replacement of polyurethane and rubber panels to reduce blinding and plugging problems on flat-screen decks. It features independently vibrating wires, bonded in place with polyurethane strips, which provide more open area for increased throughput, higher production, and better efficiency in hard-to-screen applications. Flex-Thane modular panels install easily on most flat-surface screen decks. It is available in 1- by-1-foot and 1- by-4-foot panel sizes.

Derrick Corp. will introduce its high-capacity decanter, the DE-7200 Centrifuge. The machine is said to be extremely cost effective and to offer a proven solution to the traditional use of belt press technology. It is designed specifically to dewater pre-thickened solids from radial thickeners or clarifiers. The material is converted into a stackable or conveyable form and provides a closed-loop solution to settling ponds. Key benefits include minimal operator involvement, a drier end product, lower chemical consumption, and a smaller footprint.

The patent-pending pulley design for Superior Industries’ Chevron Wing Pulley can deflect threatening material, extend the life of conveyor belts, and reduce noise by nearly 50 decibels, according to the manufacturer. It’s designed to provide more reliability in tail pulley applications. A round bar wing cap design is said to prolong wear life, and its V-shape aids in bringing the belt to the center of the pulley.

Vulcan On-Board Scales will feature its new dump truck weighing system, which complements an expanding line of on-board weighing systems designed to eliminate overweight fines and to help operators increase revenue by maximizing every load. The unit is said to save time in the loading, weighing, and re-loading process and to provide accuracy within 1 percent of the gross vehicle weight. Designed for both on-road and off-road applications, a V300 meter in the cab displays either gross vehicle weight or net payload weights and alerts the driver to unsafe or overloaded conditions. Rugged pin-style load cells in the rear hinge and a hydraulic sensor for the front-lift cylinder provide the information needed to optimize loads.

Screen Machine Industries, Inc. will tout its Spyder 516T portable tracked screening plant, featuring a Caterpillar 312 undercarriage and the company’s patented SmoothStart technology. The unit’s screen box features a 5- by-16-foot double-deck, two-bearing screen with a capacity of up to 600 tons per hour. The U.S. Grade 80 steel screen box features a heavy-duty, wear-resistant plate for extra long life, while the hydraulically adjustable screen angle moves from 8 to 20 degrees to match the screen angle to material for efficient screening. The top deck accepts wire cloth, punch plate, or finger screens, and the bottom deck accepts wire cloth, harp style, or finger screens. With an optional grizzly screen, the plant can screen four different sizes of material simultaneously. A wireless remote control system provides ease of operation.

Telsmith, Inc., an Astec company, will introduce its new track-mounted primary jaw crushing plant, the Quarry-Trax Model TJ3258, at ConExpo-Con/Agg. Engineered to deliver high yields with superior reliability, the plant’s Telsmith 3258 jaw crusher features a larger gape and a 58-inch-wide crushing chamber, boosting crushing capacity by up to 15 percent over similar sized units. Unique new features include hydraulic adjustment, hydraulic tramp iron relief, and hydraulic chamber clearing, which reduce operating costs and allow an operator to safely clear the crusher and return to production in minutes. The crusher uses PLC controls for ease of operation. In the automatic mode, the crusher feed is maximized by monitoring engine load, crusher load, and feed in level in order to maintain a consistent choke feed. The crusher setting is displayed on an on-board LCD monitor and adjustments are enabled through push button controls. Options include a hydraulic hammer, 18-cubic-yard hopper extensions, a folding conveyor extension, and magnet.

Flexco will roll out its new line of DRX Impact Beds at ConExpo-Con/Agg. Engineered to maximize belt protection while offering ease of installation and maintenance, these impact beds incorporate Velocity Reduction Technology in the structure design. The multi-level support is used to absorb impact energy and minimize transmission to the belt. The DRX’s Slide-Out Service feature allows direct access to the bars and bolts for easy inspection and quick, safe maintenance when required — reducing downtime. The four-model lineup meets or exceeds CEMA standards and are said to be able to handle everything from light-duty sand and gravel applications to heavy-duty and extreme applications that combine large material and a severe drop height.

Giberson Enterprises will display its Eco-Crusher excavator-mounted jaw crusher buckets at ConExpo-Con/Agg. The line includes the BG60 for 18,000-pound or larger excavators; the BF70 for 28,000-pound or larger excavators; the BF90 for 48,000-pound or larger excavators; and the BF120 for 68,000-pound and larger excavators. Production rates range from 15 to 99 tons per hour, depending on bucket size. The bucket is designed to crush material with a maximum input product thickness of 15 inches for recycle and 10 inches for aggregate into an end product that ranges from 6 inches to 1-inch minus.

Sandvik Mining & Construction USA LLC will feature its UH440i, a highly flexible, mobile secondary crushing unit that is said to provide a quick return on investment. The “i” stands for built-in intelligence designed to ensure smart and trouble-free operation. The system features a Sandvik CH440 cone crusher and the ASRi crusher control system. It can operate independently or in a system with other units, particularly the Sandvik CM1208i primary crushing unit. The secondary is designed for quick setup and close-down and has a hydraulically foldable feed conveyor. Easily accessible maintenance items streamline regular maintenance.

Automated Access Solutions will showcase methods to improve scale house throughput, reduce labor, and extend operating hours with its Access entry stations that can process cash and credit card transactions. The company offers vehicle identification and weighing systems that can automate one or more lanes at the scale house to improve speed and accuracy. The system is designed to complement existing management systems. It is based on the Microsoft “.NET” platform and SQL Server and is said to be able to integrate with any management system. MatreX, a Web-based transaction processing system, provides real-time data, consolidates data from multiple sites, and allows users to export data into billing and management systems.

Phoenix Process Equipment Co. will highlight its aggregate fines recovery and water clarification processes at ConExpo-Con/Agg. Its recent innovation, the Ultrasep Ultra High Rate Thickener, features no moving parts and requires a small footprint. It produces high underflow solids of up to 60 percent and is designed for easy installation and relocation.

Unified Screening & Crushing will introduce Superflow, an advanced combination of wire cloth and urethane support strip. This special hybrid product expands the company’s Unified Clean Screen product line, which includes wire cloth, rubber, and urethane screen surfaces and is designed to improve throughput.

Richwood will promote its new technology to protect conveyor belts — the Combi-Pact Impact Saddle. Designed to address the shortcomings of earlier technology, it is a bolt-in replacement for conventional idlers and is distinguished by a curved surface supporting the whole area of belt in contact. Installed in arrays, the saddle can replace impact beds or cradles of many feet in length. They are built with a unitized steel frame to provide strength and with ultra-high molecular weight polyethylene impact segments that match the conveyor’s trough exactly to protect the full width of the belt. No part of the conveyor is left unprotected. The density of the segments is said to be instrumental in preventing alien materials from becoming embedded in the belt carcass. Designed as a direct replacement for conventional idlers, it can be used in all types of applications ranging from light to heavy duty.

IROCK will feature its RDS-20, which it describes as the most powerful, versatile, compact crushing and screening system on the market. Suitable for processing aggregate, demolition debris, and recyclable materials up to 500 tons per hour, its patented Hydraset Hopper System is designed to attach and remove the hopper/feeder module as a unit without the aid of any outside lifting devices. This allows the hopper/feeder module to be detached and transported in minutes. With independent power to operate the removal or installation process, it can be loaded on a trailer, moved to a remote jobsite, and reassembled to the crushing unit safely and easily by a single person.

Impact Service Corp. will highlight its ISC Model 103-VSI Crusher during ConExpo-Con/Agg. For use in secondary and tertiary crushing applications, it features a six-shoe, 51 1/2-inch impeller table. It is said to offer tremendous tonnage capability with high reduction ratios and to produce material with excellent particle shape. The crusher can handle feed sizes of up 8 inches and produces up to 800 tons per hour. ISC’s product line is designed for ease of transport for portable applications or minimal foundation requirements for permanent applications.

Eriez will roll out its Metalarm MA3600, a metal detector that uses pulse induction technology to offer balanced coil detection sensitivity and performance. Engineered for installation in quarries and mines, it incorporates several key features. Higher detection sensitivity ensures that even the smallest problematic tramp metal can be detected; providing better protection for crushers, screens, and conveyor belts. The metal detector is microprocessor based with self diagnostics and fault indication as standard. Significant is the hardware and software-filtering algorithm that gives enhanced noise immunity from plant equipment such as motors, inverters, and screens. The new unit includes two models: the Eagle and the Hawk. The Hawk coil is for standard applications with a sensitivity that is typically 5-percent plus of aperture height, and the Eagle coil is used when especially high sensitivities are required, nominally 2-percent plus of aperture height.

Fintec Crushing and Screening Ltd. will introduce its Fintec 1080 track-mounted cone crusher system to the U.S. market. The mobile 385 horsepower cone features high strength and capacity with high-reduction performance, all-in feed, and direct hydraulic drive to produce material of desirable shape and quality. The plant features the Sandvik H3800 crusher, developed with the Sandvik CSC (cubical shape crushing) technique to produce high quality material for tight specification standards. With a hopper capacity of 6.5 cubic yards and a maximum feed opening of 7-1/2 inches, the hydraulic-adjust crusher will allow a coarse closed-side setting (CSS) of 1/2 inch to 1-1/2 inches and a medium CSS of 1/3 to 1 inch. A level monitor controls the feed rate to ensure choke feeding, while a semi-automatic setting regulation system optimizes production and tracks liner wear. A 40-inch-wide hydraulic feed conveyor allows easy access from above the crusher for maintenance while a remote radio console controls the hydrostatic crusher drive.

Belt-Way Scales, Inc. will highlight the ease of operation and calibration among its conveyor belt scales. Design modifications to the load cell assemblies — the scale’s weighing components — have reduced installation time on both standard conveyors and low-profile portable equipment. In addition, the scale may be easily removed and installed on another conveyor, if needed. A new self-aligning weighbridge assembly and updated electronics contribute to the unit’s overall performance.

Cardinal Scale Mfg. Co. will highlight its SB-500 Remote Weight Displays, which provide a highly visible readouts as well as traffic coordination. Large 5-inch-high LED digits, 2-inch-high units, and mode provide ease of visibility during scale house and ticketing procedures. A variety of connectivity options are available including serial, fiber optic, wireless, Ethernet, or Wi-Fi, while an auto-learn mode is available for most indicators. The NEMA 4/IP65 enclosure features a built-in rain hood to protect against the elements and a stainless steel enclosure is optional.

Tandem Products, Inc., with its Rhino Hyde Division, will highlight its polyurethane products for the concrete, aggregate, and mining industries. Its products include liners for concrete batch plants, hoppers, chutes, and screening media for modular and crown decks, which include Rhinowire, Rhinogrid, as well as Rhino membranes and screens.

At ConExpo-Con/Agg, Miller will expand its entry into the North American market with a range of compact quick couplers and task baskets. The new quick coupler range will include three versions: mechanical, hydraulic (semi-automatic with mechanical back-up safety pin), and universal fully hydraulic (operated completely from the cab). Each coupler is designed to provide fast, on-site attachment changeover. Operation from the cab increases time savings, productivity, and operator safety. The compact quick coupler range features a universally compatible design that allows for quick operation with a greater range of attachments.

Dredging Supply Co., Inc. will use ConExpo-Con/Agg to feature Prospector, a mine management software program. The program is a real-time, operator-friendly system designed specifically for hydraulic dredge operations. The non-PC-based tracking system consists of two independent GPS WAAS antennas, a depth transmitter, a dredge-mounted touch screen, and an Excel-based program for mine management. The GPS receivers and intelligent display indicate and record where and how deep the deposit has been mined. The user also has the ability to set up a mine plan for the reserves, which will track the dredge’s position and performance.

Metso Minerals will launch its Lokotrack LT200HPS plant to the U.S. market during ConExpo-Con/Agg. The new cone plant is built around the Nordberg HP200 and can process up to 275 tons per hour thanks to its 8-inch feed opening. It is said to produce a highly cubical end product and to have excellent reliability. Its Cat C-13 diesel engine meets Tier 3 emission standards and creates 416 horsepower at 2,100 rpm. Variable crusher speed allows the user to optimize the speed for specific liners and feed stock. Two screen options are available: single- or double-deck detachable screens. The standard single-deck screen features a large screening area of 3.9 square meters and mesh size options ranging from 20 to 60 millimeters. The optional double-deck screen enables the simultaneous production of two products. The rotation of the screen can be changed, and the screen module has a hydraulic opening for screen mesh changes. Optional recirculating conveyors allow for closed-circuit operation. The plant also features the IC600 interactive, intelligent control system to monitor material flow to the cone.

Brunner & Lay, Inc. will showcase its wide range of demolition tools for use with most types of heavy-duty, boom-mounted breaker attachments. The tools are manufactured from high-quality steel that is heat treated in modern pit-type furnaces to create the hardness, impact strength, and durability required to face the tough conditions in mine and quarry environments. The tools include points, chisels, blunts, and other specialized working ends.

Columbia Steel Casting Co., Inc. will tout its expansive list of jaw and cone patterns for wear parts, which allow for optimum crusher performance. A recent audit showed that more than 1,900 jaw designs for more than 380 jaw crusher models are currently available. When counting cone crusher designs, the company included only those with bowl liners and determined it had more than 1,100 designs for more than 120 cone crusher models available, including more than 50 designs for the Nordberg 4-foot short head cone crusher.

In its first worldwide show since being acquired by Sandvik, Extec will feature the S-7, the largest model in its S-Series. The machine features the same double-screen design as the smaller units in the series, but boasts a triple-deck configuration along with an additional side conveyor. Along with a large feed hopper with optional double-deck vibrating grid and a set of extended conveyors, these features are said to make the S-7 the most productive mobile screen in its class. With a transport weight of 85,142 pounds, the unit is powered by a Deutz BF4M 2012 diesel engine with 74.9 horsepower that meets or exceeds all known emission regulations. It is carried on a large, durable chassis that provides enhanced strength and rigidity while a self-loading hydraulic bogie provides an independent transport capability without the need for low loaders.